Form for concrete constructions



June 23, 1953 c. A. coMME-r ErAL FORM FR CONCRETE CONSTRUCTIONS 4Sheets-Sheet l Filed Sept. 13, 1948' INVENToRs COMMET F. MERE/MAN BY i IZ C. A. C.

ATTORN EYS.

June 23, 1953 c. A. coMME'r ETAL 2,642,645

FORM FOR CONCRETE CONSTRUCTIONS Filed sept. 13, 1948 4 snezs-Sneet 2mvENToRs. C. A. COMMET c. F. MEER/MAN ATToRN EYs.

June 23, 1953 c. A. coMMl-:T ETAL 2,542,645

FORM FOR CONCRETE CONSTRUCTQIONS I A Filed Sept. 15, 1948 4 Sheets-Sheet5 |NvENToRs-- c. A. CoM/WET C- F Miele/MAN ATTORNEYS.

June 23, 1953 c. A. coMMET ETAL 2,642,645

FORM FOR CONCRETE CONSTRUCTIONS v Filed sept. 15, 1948 4 Sheets-Sheet 4lNVENToRs,

i C- A. COMME-r ATTORNEYS,

Patented June 23, 1953 UNITED STATES PATENT OFFICE 2,642,645 l FORM FORCONCRETE ooNs'rRUo'rIoNs Charles A. Commet, Bowdle, S. Dak., and ChesterF. Merriman, New York, N. Y.

Application September 13, 1948, Serial No. 48,986

9 Claims. (Cl. 25-131) This invention relates to improved means for theconstruction of buildings, etc. f

The primary object of this invention is the provision of improved formwork for concrete Wall construction.

A further object of this invention is the provisio-n of improved innerand outer form work for the fabrication of monolithic wall construction.

Other objects and advantages of this invention Will be app-arent fromthe following detailed description.

In the accompanying drawings, forming a part of this specification andwherein similar reference characters designate corresponding partsthroughout the several views- Figure 1 is a fragmentary verticalsectional view showing an initial step inthe fabrication of a wallstructure.

Figure 2 is a view similar to Figure 1 with additional form work addedin a succeeding step.

Figure 3 is a horizontal cross sectional view taken thro-ugh the formwork necessary toproduce the multi-layer bonded type of monolithicstructure'.

Figure 4 is a horizontal cross sectional view taken through a portion ofthe form Work and wall structure showing a core form poured or filledwith insulation material such as aeroconcrete.

Figure 5 is a cross sectional view similar to Fig ure 4 showing the formwork in an additional step wherein structural concrete is poured in theform work at the weather side of the Wall structure.

Figure 6 is a fragmentary horizontal cross sectional view taken throughthey completed monolithic wall structure.

Figure '7 is a fragmentary view showing the application of certainopenings in a wall structure formed according to this invention, such asfor doors, Windows and the like.

Figure 8 is la horizontal cross sectional view taken through a dooropening of the wall structure showing associated details.

Figure 9 is a fragmentary cross sectional view showing certain form workwhich is essential in providing window openings where it is necessary topour concrete beneath the window opening to form part of the monolithicwall structure.

Figure 10 is a side elevation o-f a type of core form which may be usedfor providing the central insulated wall section.

Figure 11 is a fragmentary horizontal cross sectional view showing amodified form of monolithic wall structure which differs somewhat fromthe wall structure of Figure 6.

This application is a division out o-f our oopending application SerialNumber 761,832, led July 18, 194'?.

In the drawings, wherein for the purpose of illustration are showndifferent types of wall structures and various forms for the productionthereof, the letter A may generally designate a preferred type ofmonolithic wall structure shown in Figure 6. A modified form of wallstructure B is shown in Figure 1l. For the formation of either of thesewall structures a foundation C is provided. Upon it is then set up aweather side form structure D, as shown in Figure l. Thereafter, thecore form structure E is set up upon the foundation C', and nally theroom side form structure F is placed. Of course it may be opti-onal asto the initial placing of the weather side form structure D and the roomside form structure F. Either one may be placed first, but succeedingthe initial placing of either the room or weather side form structure,the core form structure E must be placed. The monolithic masonrystructure for the form of invention A contemplates a structural concretezone or section G at the weather side of the wall, a light-weightconcrete zone or section H at the room side of the masonry structure,and the intermediate insulation wall portion K of aeroconcrete or otherinsulation material.

The foundation C is preferably of the nature shown in fragmentarysectional views of Figures 1 and 2 and includes along the upper, outerand inner perimeters or edges thereof footings or recesses 20 and 2 l.

It is the intention to provide the weather side and room side forms Dand F in sections which, for conventional building work, may be 9 inheight and 8 to 16 long. Having preformed panels of this size enablestheir use for successive wall structure. Inthe main, these forms aremade up of 4" x 4" vertical studding 22 to which diagonal sheathing 23is suitably connected. A layer of cheap composition board or plywood 24is appropriately secured upon the inner surface of the sheathing 23, forthe purpose of providing a smooth surface upon the exposed sides of thewall structure when completed. The weather side and room side form workpanel may be initially supported in any approved manner until the coreform E has been placed. Subsequently the panels of the form work D and Fare connected by foundation secured bolts 25 and other cross boltstructures 26 thereabove. One of these may be placed one-third the wayup from the foundation and another adjacent the top of the wall, or theymay be provided in any desired number consistent with the height of thewall structure. These cross or tie bolt structures need not be of theform shown in the drawings since they can -be made with removable endsafter a structure well known in this art so as to eliminate any metallicbolt or tie rod connections after the wall is completed and the formshave been removed.

The core form E may be of a shape and strucconcrete to form the wallsection G. This insulation strip 45 can be omitted in warm climates, ifso desired, and it is of the common type of commercial insulation strip.

The assemblage of the various form works upon the foundation is shown inFigure 3. In. the core form El may be placed material having desiredinsulating,v qualities. We may use suitable earth material in drycondition, or sawdust, clay, insect killing composition in pellet orgranular form, or comminuted straw or cornstalks. Prefture to suit thetype of masonry wall which being constructed and also to suit the typeof insulation material which it receive'sfto provide the insulating coreof the wall.

, '15 One approved type is that shown in Figures 3 tofG inclusive. Y Itis intended to run this core for the height of the wall and individualcore forms may be placed between adj acently disposed tie rodslengthwise of the wall, as shown in Figure 3. Aswill besubsequentlydescribed the coreI fornr'mayjbe extended the full length of the wall,as for the'type of structure shown in Figure 1l;

In the core form E, we provide an outer vertically 'disposed wallportion 30 having end wall portions 3| and 32. -These parts may beintegral and preferably they are of creosote treated wallboard or othercheap Vbrebo'ard construction, possessing sufficient rigidity towithstand the pressure exerted by the core which'is being formed. Theend walls 3l and 32 may be flanged at 33v and to these flanges aresuitably connected steel tie rods 35. At the inner sides of the flanges33 is connected steel wire mesh or metallic lathing 36 for the entirelength and width of the core form E. As a connecting means for thevarious form 'parts we provide cross rods or bolts 31 which in thespaceV where Ythe structural-.wall section is to be formed are providedwith anchoring heads 39 to bond the structural wall section to the otherwall sections. OfA course there would be no objection to providing thewall 30 of the core form of open work, such as steel mesh, in order tobond the structural concrete wall with the aeroconcrete wall portion.Therefore, wherever the term bond is used, it isto be sufficientlybroadly' construed to include also an anchoring bond.

Removablerspacing strips or members 40 are provided between the outer orweather side panel form D and the core formyand also between the roomside form F and the core form, as is shown in the drawings.

In cold climates where frost is apt to creep through the wall structure,it preferred to insulate the structural concrete wall section G from theroom side light-weight concrete'section H. To that end, insulationstrips 45 are provided and they are held in position by collapsible Aframes, designated at L in the drawings. These frames are verticallypositioned at the end spacing of the core forms F where the cross rodsbetween the weather side and room side forms are placed, and theyconsist of a core form abutting panel 46 having legs 41-hing edlyconnected thereto and cross turnbuckles 48 for contracting the legs tofill the space between the core forms and the room side panel work F, asshown in Figures 3, 4 and 5 of the drawings. In the space between theends of the core forms and against the panel 46 is disposed theinsulation strip 45 which may be placed before pouring begins or afterthe core forms have vbeen filled and Vjust before the pouring of thestructural Verably, we use a commercial type of aeroconcrete which ist asponge-like material having only a fraction ofthe relative density ofstructural concrete. It is fabricated of sand, water and a iiuffingchemical well known to those skilled in the -art relating to masonryconstruction. rI'his provides a cellular type wall section having high 7insulation qualities as is designated by the letter K in the drawingsshowing the form of invention A. vIlie'fm'aterial forming theco're orwall section K may be pumped from the top` of the wall structure in'tothe form by conventional concrete pumping' mechanism, and in the case ofother materials which do not bond similar to aeroconcrete,such may betamped tothe desired degree. The wall lin V.this stage is shown inFigure4.

Succeeding the placement of the insulationcore of tthe monolithicwallistructure, the outer wall section G may be poured. The materialis'of high quality concrete of a nature which may approximate 4Athreethousand' to four thousand pounds per square inch after setting fortwentyeight days. This is not intended to be a limitation but ismerelycited to show a structural relation withl respect to the otherwall zones or sections. 1f desired, we can use'steel rod or otherreinforcing expedients inthe wall section G.

At this point itis to' vbe noted that the structural wall section GIincludescross extensions designated at 50 in the-drawings projecting inthe direction of the room wall section H and located between the ends ofthe cores formed by VVthe'type of form E. These transverse walls 50 maybe suitably reinforced if desired, and if the'insulation strips 45 arenot used, the cross walls 50 may be bonded with the material of the roomside light-weight concrete wall section I-I.

Subsequent' to placement of the structural concrete wallY sectionorzoneG, the inner wall section I-I is poured. All of the pouring stepsmay be accomplished by means of conventional concrete pump guns from thetop of the wall form; The interior wall lsection His of lightweightconcrete consisting of cement, sand, water and a Vermiculite type ofaggregate which, asis-*conventionally known, expands Awhen the sand andwater become active. Vermiculite aggregate, as is well known, isobtained from vermu'cilite ore expanded or exfoliated from nine tosixteen times'normal size, and it weighs from six to ten pounds percubic foot after exfoliation,` 'Vermiculite ore is-amicaceous,non-rnetallic mineral which possesses millions of cells in `expandedcondition. Ithas high insulating qualities and 'is sound proof. Itsnature will enable the facile driving of nails or other securingexpedients thereinto.

The wall section or zone H is directly bonded with the core section Kand because of the use of wire-.mesh or metal lathing 36. If desired, wevmay hang a,curt an of some "fabric inside of the metal lathing sprayedwith hot asphalt.

It is to be understood that before pouring the structural concretesection G the spacing forms 40 are removed and that is also true priorto pouring the wall section I-I, and in the latter case the collapsibleframes L are also removed. A horizontal cross section of the completedwall A is shown in Figure 6 and it is noted that the cross rods 35 mayalso be removed so that the only portion of the form work which is lostis the relatively cheap parts Sli-33. 'I'he metal lathing addsappreciably to the structural characteristics of the wall.

In the modied type of wall structure B, the

weather side and room side forms are used similar to that abovedescribed, but the core form is construed diierently so as to provide acontinuous section of aero concrete. To that end breboard forms areprovided which include an outer iibreboard form wall 69 having crossWall providing sections 6l of a U-shaped cross section, at the desiredintervals where it is intended to provide cross walls or ribs upon thestructural wall section G. The inner breboard Wall 63 may present ahorizontally corrugated appearance, to give added strength to thelight-Weight concrete section H of the wall structure B, and this formof the breboard wall 93 is maintained through the provision of steelrods 65, as shown in Figure 11.

The Wall sections G', K and H are formed in a sequence of steps such asabove described for the monolithic wall structure A, and portions 6| ofthe wall form 69 provide cross wall portions which reinforce the wallstructure. Also it is to be noted that the aeroconcrete wall section orzone K is continuous and, of course, that is also true of the structuralconcrete wall section or zone G and the `light-weight concrete wallsection or zone H. Suitable cross rods 'H may be provided, having thesame anchoring expedients as those above described for the form of wallA.

Referring to fabrication of the monolithic wall structure so as toprovide door and window openings, as shown in Figures 7 and 8, along thesides of the door opening designated at 80 in the drawings and also onthe sill, we provide creosoted strips, preferably 2 x 4 in size. Thestrips 8l are positioned along the sides of the opening 89 and a sillpiece 82 is provided. These are centrally positioned and may be used forattaching suitable jambs, stiles, door casings, etc. For a windowstructure 9D and the like, We utilize a box type form shown at 9| inFigure 9, which may be cooperatively disposed with respect to theconventional inner and outer forms designated at 92 and 93. Of-courseside strips 95 may be used for attaching Window sashes thereto, whichare similar to the pieces 8l above described. The strips 8l and 95 maybe suitably anchored in the structural concrete wall section by means ofmetallic clips 96 shown throughout the different views. The box 9| mayhave a floor 91, shown in Figure 9, provided with suitable openings 98through which the nozzles of concrete pumping guns may be extended forpouring the concrete of the various wall sections into the wall belowthe normal window space being formed.

It will be noted from the drawings that when the outer side and roomside forms are removed, the marginal edge of the top surface of thefoundation will be exposed inwardly of the footing recesses 20 and 2|.This may be used for L 6 any finish desired, such as plastering, moldingor the like.

Various changes in the shape, size and arrangement of the forms, as wellas, the panels or wall sections formed may be used, as well asvariations from the specific steps of the method above enumeratedwithout departing from the spirit of this invention or the scope of theclaims.

We claim:

1. In a form structure for the fabrication of concrete walls, thecombination of a Weather side wall form, a room side Wall form in spacedrelation with respect to the weather Vside wall form, both of said wallforms extending thruout the height of the concrete wall to be formed,"a

plurality of individual compartment providing core forms located in thespace between the removable weather and room side wall forms and inspaced relation with the latter and extending thruout the height of thewall to be formed, removable means in the spaces between said core formsand the weather side and room side wall forms for holding the properspacingk thereof, said core forms being relatively rspaced from eachother, and removable forms located at the room side form wall coveringthe spaces between the spaced core forms at the ends thereof.

2. In a form structure for the fabrication of concrete walls, thecombination of a removable weather side wall form, a removable sidewalll form in spaced relation withrespect to the weather side wall form,both of saidwall forms extending thruout the height of the concrete wallto be formed, a plurality of relatively end spaced individualcompartment providing core forms located in the space between theremovable weather and room side wall forms and in spaced relation withthe latter and extending thruout the height of the Wall to be formed,removable means in the spaces between said core forms and the weatherside and room side wall forms for holding the proper spacing thereof,removable forms located at the room side form wall covering the spacesbetween the spaced core forms at the ends thereof, and tie means exrtending thru the spaces between the end spaced core forms and removablyanchored to said weather side and room side Wall forms. g

3. In a form construction for the fabrication of masonry walls, thecombination of weather side and room side relatively spaced removablewall forms, core forms each providing compartments therein for receivinga masonry core, saidcore forms being located in the spaces between thei'lrst mentioned wall forms and in spaced relation therewith, the coreforms at the sides thereof facing the room side wall form beingconstructed of foraminous material to enable the same to bonddirectlywith cementitious material adapted to be placed in the spacebetween the same and the removable room side wall form.

4. In a form construction for the fabrication of cementitious walls thecombination of removable weather side and room side wall forms adaptedto extend thruout the height of the wall to be formed, a plurality ofvrelatively spaced compartment providing core forms located in the spacebetween the Weather side and room side wall forms and in spaced relationwith the latter, removable means to hold said core forms in spacedrelation with respect to the weather side and room side wall forms,removable forms at the room side wall form closing the spaces betweenthe ends of the core forms, and an insulation strip in each of said endspaces between the ends of the core forms disposed at the last mentionedremovable forms in position to close off said spaces in facing relationwith the weather side wall form. Y

5. A form structure for the fabrication of cementitious walls comprisingremovable weather side and room side wall forms disposed in spacedrelation to define the thickness of the wall, vertically disposed crossform walls in the space between the first mentioned wall forms to dennewall openings, and nailing strips in spaced relation in the spacesbetween the weather side and room side wall forms and immediatelyadjacent to the cross wall forms and directly at the inner sidesthereof.

6. A form structure for the fabrication of cementitious walls comprisinga foundation, removable weather side and room side wall forms upon saidfoundation disposed in spaced relation to define the thickness of thewall, vertically disposed removable cross form walls in the spacebetween the rst mentioned wall forms to denne a window opening, nailingstrips in spaced relation in the spaces between the weather side androom side wall forms and immediately adjacent to the cross wall formsand directly at the inner sides thereof, and a bottom wall form for thewindow opening disposed in the space between the cross Wall forms andspaced above the foundation and defining the bottom of said opening andhaving openings therethru for disposition of cementitious material intothe space below said bottom wall upon said foundation.

7. In a form construction for the fabrication of a concrete masonry wallhaving a weather side structural concrete section, a light weightconcrete room side section, and a core section of insulation concrete,the combination of a core form construction for receiving insulationconcrete having spaced side walls and relatively spaced end walls atintervals along itslength, a room side wall form spaced from the facingside wall of the core form, a weather side wall form spaced from thefacing side of the core form, said core form end wall spaces directlyopening into the space between the weather side wall form and the coreform to permit structural concrete when poured to also enter betweensaid core form end walls.

8. In a form construction for the fabrication of a concrete masonry wallhaving a weather side structural concrete section, a light weightconcrete room side section, and a core section of insulation concrete,the combination of a core form construction for receiving insulationconcrete having spaced side walls and relatively spaced end walls atintervals along its length, a room side wall form spaced from the facingside wall of the core form, a weather side wall form spaced from thefacing side of the core form,

said core form end wall spaces directly opening into the space betweenthe weather side wall form and the core form to permit structuralconcrete when poured to also enter between said core form end walls, andcollapsible and removable forms in the space between the core form landthe room side wall form at the location of said spaced end. walls of thecore form to block oft" access of the space between said core form endwalls to the space between the core form and room side wall form.

9. In a form construction for the fabrication of a concrete masonry wallhaving a weather side structural concrete section, a light weightconcrete room side section, and a core section of insulation concrete,the combination of a core form construction for receiving insulationconcrete having spaced side walls and relatively spaced end walls atintervals along its length, a room side wall form spaced from the facingside wall of the core form, a weather side wall form spaced from thefacing side of the core form, said core form end wall spaces directlyopening into the space between the weather side wall form and the coreform to permit structural concrete when poured to also enter betweensaid core form end walls, and collapsible and removable forms in thespace between the core form and the room side wall form at the locationof said spaced end walls of the core form to block off access of thespace between said core form end walls to the space between the coreform and room side wall form, the side of the core form constructionfacing the room side form being of foraminous metallic material topermit the bonding of the light weight concrete room side section andthe insulation concrete section of the coreform construction.

CHARLES A. COMMET.

CHESTER. F. MERRIMAN.

References Cited in the file of this patent UNITED STATES PATENTS NumberName Date 1,003,591 Fry et al Sept. 19, 1911 1,030,480' Packard June 25,1912 1,488,726 Alexander et al.4 Apr. 1, 1924 1,730,533 Rose Oct. 8,1929 1,852,049 Graef Apr. 5, 1932 2,007,689 Merrill July 9, 19352,091,542 Frati Aug. 31, 1937 2,109,009 Hadley Feb. 22, 1938 2,187,959Williams Jan. 23, 1940 2,251,499 Pelton Aug. 5, 1941 2,262,899 MechlinNov. 18, 1941 2,309,147 Wilkinson Jan. 26, 1943 2,318,058 Colburn May 4,1943 2,455,455 West Dec. '7, 1948 2.476.135 Colburn July l2, 1949

